| 1 Remove saddle. |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 2. Remove side panels |
or at least try not lose them, a fix for those is on tips I think!
|
| 4. Disconnect vacuum pipe. Best done from the carb end. |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 5 Disconnect fuel pipe |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 6 Undo 12 mm Bolt from Fuel Tank. |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 7, Remove Fuel Tank. |
Mechanic.... Northern Nick
Photos, & words by Si
|
| 8. Using a crosshead screwdriver, loosen the clamps from the rear of
the air box |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 9. Loosen the clamps holding the air box to both carbs |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 10. Wriggle the air box free from the machine. |
Mechanic.... Northern Nick
Photos, & words by Si
|
| 11. Using a crosshead screwdriver, loosen the clamps which hold the
carbs into the inlet rubbers |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 12. Wriggle the carbs from their rubbers. Note you do not have to undo
the cables. I usually put over a plastic bag over them to stop debris/water
getting into them. |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 13. Remove the four spark plug caps. and tuck them, still
attached to the HT leads away from the engine (I usually put them near
the coils, it stops them from getting in the way or getting damaged). The
HT leads are usually numbered, but it is not easy to get them in the wrong
plugs as they have different caps for right and left. The shorter two leads
go to the front pot, and can't reach to fit into the rear one. |
Mechanic.... Northern Nick
Photos, & words by Si
|
14. Using a crosshead screwdriver, undo and remove the screw holding
the rev counter cable from the rocker box cover in the front pot.
Remove the cable and place the screw back into position to stop
it being getting lost. |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 15. remove the nuts holding on the exhaust(s) to the heads |
Front pot
Rear pot
|
| 16 & the bolt holding the silencer from the foot peg carrier. |
|
| 17, wriggle the exhaust(s) free. |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 18, Drain the coolant into a suitable container. (I usually find the
lowest part of the machine and undo the main pipe connection, cost common
clip here is the trusty "jubilee" type), here though, it is the grip
type. Just use the pliers to pull the spring grip together and wriggle
the grip up the pipe free from the spigot, then wriggle the pipe up the
spigot. |
Mechanic..... Northern Nick
Photos, & words by Si
|
| 19, Undo the water hose clips from the rocker box of both heads, two
on the rear rocker box, one one the front.. Use a pair of pliers to squeeze
the clips and pill towards to the frame, then using the pliers, pull the
pipes up from the spigots. |
 
Mechanic..... Northern Nick
Photos, & words by Si
|
| 20. Trace the two wires from the right hand side of the radiator, to
the two bullet connectors which you should find under the two little plastic
covers, just to the rear of the head stock. Pull them apart carefully and
check for corrosion while you have them apart. These wires do the fan and
the fan switch. |
Under Construction!
Mechanic,
photos, & words: Si
|
21, undo the clip holding on the top rear of the water radiator. Then
using a tyre lever against the down tube, and the top back, metal part
of the radiator.
Note: Do not the lever against
the rear of the "grill" part of the radiator, this part can be easily get
damaged!
When pipe connection has pulled forwards
and free of the pipe. Pull the top front of the radiator forwards and up,
the radiator and the fan should come free, and be stored into a safe place. |
Under Construction!
Mechanic,
photos, & words: Si
|
| 22. Undo trace the rest of the wires which you can see, connect the
engine to the rolling chassis. The main Earth form the Battery; the live
from the solenoid; the generator wires connection box, which have
should be on a brace bar between the main tubes under where the saddle
sits. |
Under Construction!
Mechanic..... Northern Nick
Photos, & words by Si
|
| 23. Remove the lower clutch cable, by pulling the arm towards the front
of the machine and pull the cable nipple through the slit on the end of
the arm. |
See clutch cables:
external adjusters.
Mechanic..... Northern Nick
Photos, & words by Si
|
Owner, not to be named (in shame of letting it get this bad... 10,000
without a service)
Mechanics..... Northern Nick / Si
Photos, & words by Si.
Under Construction!
|
©